2003 SSANGYONG MUSSO oil

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °

OM600 ENGINE MECHANICAL 1B3-93
FLYWHEEL
Preceding Work : Removal of the transmissionRemoval of the clutch
1 Oil Pan
2 Straight Pin
3 Flywheel 4 12-Sided Stretch Bolt
............ Check, 45Nm + 90 °
5 Drive Plate (Automatic Transmission)
6 Flywheel (Automatic Transmission)

1B3-102 OM600 ENGINE MECHANICAL
CheckingNotice The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it doesnot need to be repaired. Determine the malfunctions in valveclearance compensation device with noise through following
tests. If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4 minutes.
2. Stop the engine. After 5minutes, check the engine oil level and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cylinders.
5. Using a drift, lightly press the valve tappet and measure clearance between the cam and valve tappet. Notice If the clearance exceeds 0.4mm, replace the valve tappet.
6. If a valve tappet moves down too far in comparison to the others, replace the valve tappet.
7. Rotate the engine and check the remaining valve tappets.
Notice
Unnecessary rotation of the engine will damage the valve tappets.
Do not rotate the engine by using the camshaft sprocket bolt or to the opposite direction of the engine rotation.

OM600 ENGINE MECHANICAL 1B3-103
VALVE TAPPETS Preceding Work : Removal of camshaft1 Valve Tappet
2 Cylinder Head
3 Oil Gallery 4 Seal
....................................................... Replace
5 Screw Plug
Tools Required 102 589 03 40 00 Magnetic Bar

1B3-104 OM600 ENGINE MECHANICAL
Replacement Procedure
1. Pull out the valve tappet (1).Magnetic Bar 102 589 03 40 00
2. Remove the plug (5) and blow compressed air into the oil gallery (3). At this time, check that the outlet bores(arrow)
at the seat of the valve tappet are clear.
3. Replace the seal (4) and tighten the plug (5).
4. Insert the new valve tappet.
NoticeCoat the valve tappet with oil.

OM600 ENGINE MECHANICAL 1B3-111
6. Remove the spring retainer(3) and spring (4).
7. Check the valve spring and replace if necessary.
8. Insert valve spring (4) with the color coding (arrow) facingdown and insert valve spring Retainer(3).
9. By press the spring retainer(3) with press lever (90), install the valve cotters with magnetic finger (10).
Press Lever 667 589 00 31 00
Magnetic Finger 116 589 06 63 00
10. Remove the supporting bar.
11. Remove the holding wheel (7) from the timing chain (5). Holding Wheel 603 589 01 40 00
13. Coat the valve tappet with oil and install it. Magnetic Bar 102 589 03 40 00

1B3-130 OM600 ENGINE MECHANICAL
10. Measure distance ‘z’ (cylinder head cover parting surface
- valve stem).
5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve guide.
7. Insert the valves (1) into the valve guides according to
marking.
8. Measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7 mm
Notice If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
Diameter ‘w’ 38 ± 0.2 mm
or 37.6 ± 0.2 mm

OM600 ENGINE MECHANICAL 1B3-139
CAMSHAFT Preceding Work : Removal of cylinder head cover
1 Bolt............................................................ 25Nm
2 Washer
3 Camshaft Bearing Cap
4 Camshaft
5 Dowel Pin
6 Locking Washer
7 Timing Chain 8 Cylinder Head
9 Oil Pan
10 Camshaft Sprocket
11 Washer
12 12-Sided Bolt (M11) ... ..........Check, 25Nm + 90 °
13 Gasket ................................................... Replace
14 Chain Tensioner ........................................ 80Nm